Fruit in a bubble wrap mat

Abstract

A package for compartmentalized preservation of harvested fruit or vegetables and methods are disclosed. The package may include a first flexible polymer film, comprising integral molded or vacuum formed cups configured to hold a fruit or vegetable, wherein the integral molded or vacuum formed cups can be collapsed into a plane of the first polymer film or extended from the first polymer film; and a second flexible polymer film configured to overlay the first polymer film. In some embodiments, the cups containing the fruit or vegetable may be inflated and sealed to form protective bubbles.

What is claimed is: 
     
       1. A method for packaging fruits or vegetables, the method comprising:
 unspooling a first flexible polymer film in a form of a flat sheet comprising cups, wherein each cup is configured to be expanded from a collapsed state disposed within the flat sheet to an expanded cup, comprising a depth and a circumference configured to accommodate the fruits or vegetables; 
 expanding each cup from its collapsed state cup disposed within the flat sheet to an expanded cup by a flow of compressed gas; 
 placing the fruits or vegetables into the expanded cup; 
 unspooling a second flexible polymer film; 
 overlaying the first polymer film and the expanded cup holding the fruits or vegetables with the second polymer film; 
 partially bonding the second polymer film to the first polymer film, such that at least one gas conduit is formed for each cup between the first and second polymer films allowing air to flow into each expanded cup; 
 inflating the expanded cups by pumping a gas through the at least one gas conduit, thereby forming inflated cups; and 
 sealing the at least one gas conduit, thereby sealing the fruits or vegetables within each inflated cup, thereby forming a sealed package. 
 
     
     
       2. The method of  claim 1 , further comprising forming perforations between the sealed cups, thereby allowing tearing off one or more single sealed cups. 
     
     
       3. The method of  claim 1 , further comprising positioning at least one of a gas absorbing or moisture absorbing activated pads in fluid communication with at least some of the cups. 
     
     
       4. The method of  claim 3 , wherein the at least one of a gas absorbing or moisture absorbing activated pads are positioned within the at least one gas conduit and held in place using a binder gum or a pectin, or the at least one of a gas absorbing or moisture absorbing activated pads are positioned within a depression along a bottom or side surface of the expanded cups. 
     
     
       5. The method of  claim 4 , wherein the binder gum is selected from the group consisting of gum Arabic, guar gum, Acacia gum, tamarind gum, locust bean gum, and xyloglucan. 
     
     
       6. The method of  claim 1 , wherein the gas comprises air, CO 2 , N 2 , hydrogen sulfide, steam, or any combinations thereof. 
     
     
       7. The method of  claim 1 , wherein the gas comprises hydrocarbon volatiles. 
     
     
       8. The method of  claim 1 , wherein the fruits are selected from the group consisting of bananas, apricots, mangoes, damsons, nectarines, peaches, apples, grapes, figs, kiwis, pears, tomatoes and plums. 
     
     
       9. The method of  claim 1 , wherein the partial bonding comprises applying adhesive by hot glue melt or welding, or applying pressure and heat to the polymer films. 
     
     
       10. The method of  claim 1 , wherein the pumping is performed using food grade pressurized bottled gas cylinders. 
     
     
       11. The method of  claim 1 , wherein the sealing comprises applying adhesive, heat or pressure or combinations thereof to the package, thereby closing the gas conduits and forming an air tight seal. 
     
     
       12. The method of  claim 1 , wherein placing the fruits or vegetables is performed using hopper machinery. 
     
     
       13. The method of  claim 1 , further comprising cutting the sealed package, thereby forming a sheet of sealed packages for layering. 
     
     
       14. The method of  claim 13 , further comprising layering the sheets of sealed packages into boxes or a retail display, such that a top layer of the sealed packages is overlaid on top of a bottom layer such that individual sealed cups of the top layer are placed in an orientation between the individual sealed cups of the bottom layer, thereby forming air gaps between the cups. 
     
     
       15. A method for packaging fruits or vegetables, the method comprising:
 unspooling a first flexible polymer film in a form of a flat sheet comprising cups, wherein each cup is configured to be expanded from a collapsed state disposed within the flat sheet to an expanded cup, comprising a depth and a circumference configured to accommodate the fruits or vegetables; 
 expanding each cup from its collapsed state cup disposed within the flat sheet to an expanded cup by a flow of compressed gas; 
 placing the fruits or vegetables into the expanded cup; 
 unspooling a second flexible polymer film; 
 overlaying the first polymer film and the expanded cup holding the fruits or vegetables with the second polymer film; 
 partially bonding the second polymer film to the first polymer film, such that at least one gas conduit is formed for each cup between the first and second polymer films allowing air to flow into each expanded cup, wherein at least one of a gas absorbing or moisture absorbing activated pad is positioned within the at least one gas conduit; 
 inflating the expanded cups by pumping a gas through the at least one gas conduit, thereby forming inflated cups; and 
 sealing the at least one gas conduit, thereby sealing the fruits or vegetables within each inflated cup, thereby forming a sealed package. 
 
     
     
       16. The method of  claim 15 , wherein the at least one of a gas absorbing or moisture absorbing activated pads positioned within the at least one gas conduit are held in place using a binder gum or a pectin.